US20050193866A1 - Cutting wheel with blank and manufacturing method thereof - Google Patents

Cutting wheel with blank and manufacturing method thereof Download PDF

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Publication number
US20050193866A1
US20050193866A1 US11/074,512 US7451205A US2005193866A1 US 20050193866 A1 US20050193866 A1 US 20050193866A1 US 7451205 A US7451205 A US 7451205A US 2005193866 A1 US2005193866 A1 US 2005193866A1
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US
United States
Prior art keywords
absorbing material
blank
noise absorbing
blanks
cutting wheel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/074,512
Other languages
English (en)
Inventor
Jong Woo
Hwan Lee
Eung Kwon
Seo Pyun
Mun Park
Sang Lee
Jae Jeong
Shin Kim
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SHINHAN DIAMOND INDUSTRIAL CO Ltd
Shinhan Diamond Ind Co Ltd
Original Assignee
Shinhan Diamond Ind Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from KR1020040015191A external-priority patent/KR100466509B1/ko
Priority claimed from KR1020040076567A external-priority patent/KR100671884B1/ko
Application filed by Shinhan Diamond Ind Co Ltd filed Critical Shinhan Diamond Ind Co Ltd
Assigned to SHINHAN DIAMOND INDUSTRIAL CO, LTD. reassignment SHINHAN DIAMOND INDUSTRIAL CO, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIM, SHIN KYUNG, JEONG, JAE HYUN, KWON, EUNG KWAN, LEE, HWAN CHUL, LEE, SANG JIN, PARK, MUN SEOK, PYUN, SEO PONG, WOO, JONG HYUK
Publication of US20050193866A1 publication Critical patent/US20050193866A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B29C45/14344—Moulding in or through a hole in the article, e.g. outsert moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D61/00—Tools for sawing machines or sawing devices; Clamping devices for these tools
    • B23D61/02—Circular saw blades
    • B23D61/025—Details of saw blade body
    • B23D61/026—Composite body, e.g. laminated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/0055—Shaping
    • B29C2045/0058—Shaping removing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/0055—Shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/77—Sawing equipment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49993—Filling of opening

Definitions

  • the present invention relates to a cutting wheel with blank and a method for manufacturing the same, and more particularly, to a cutting wheel with blank with an improved aesthetic appearance, which reduces vibration and frictional noise generated when a cutting wheel is used for cutting workpieces, and a method for manufacturing the same.
  • the cutting wheel is a concept generally including a diamond cutting wheel used for cutting workpieces of hard materials such as stone, steel concrete, asphalt, metal, and ceramic, a cutting wheel with cemented carbide tips used for cutting workpieces such as wood and plastic, or the like.
  • a cutting wheel is used for cutting workpieces such as stone, steel concrete, asphalt, metal, ceramic, and wood.
  • the general cutting wheel comprises a circular disk shaped wheel body 10 and cutting tips 20 which are bonded onto an outer peripheral surface of the wheel body 10 at regular intervals. A circumferential portion of the wheel body 10 is divided by gaps 12 radially formed between the cutting tips 20 .
  • the cutting tips 20 are manufactured by performing a press forming process of a mixture of diamond and metal and sintering the mixture.
  • the cutting tips 20 may also be manufactured of cemented carbide. Since the cutting wheel cuts the workpiece while rotating at several hundred to thousand rpm, a work noise therefrom ordinarily exceeds 100 dB. Frictional heat caused from friction between the cutting wheel and the workpiece considerably influences the life span of the cutting wheel.
  • a conventional blank 11 are formed in the wheel body 10 in the line shape by a laser cutting method as shown in FIG. 2 , and then, filled with silicone.
  • the silicone with which the blank 11 are filled may be removed there from due to the impact, vibration, and/or frictional heat.
  • the noise reducing effect becomes more deteriorated as compared with the initial state.
  • the blanks 11 formed in the wheel body 10 by the conventional method are slight in size and are formed so as not to intersect all of radial lines from the center of the wheel body 10 .
  • the capacity for reducing noises generated from all the directions of the cutting wheel is not so high, the noises considerably increase.
  • cutting wheels as shown in FIGS. 3 and 4 have also been suggested.
  • Korean Utility Model Laid-Open Publication No. 1999-0040662 discloses a cutting wheel for absorbing and reducing a frictional noise and vibration generated when a workpiece is cut, as shown in FIG. 3 .
  • a circular disk shaped body 10 is formed with a plurality of holes 30 , which are the same or different from each other in size and/or shape, at regular or irregular intervals. Then, the holes 30 are filled and engaged with low melting metal 40 by a sintering or press forming process.
  • the cutting wheel in which the plurality of the holes 30 formed in the body 10 are filled with the low melting metal 40 as described above, can cause the frictional noise to reduce somewhat, the configuration cannot absorb and reduce the frictional noises generated from all the directions of the cutting wheel since the holes 30 are not intersected by all of radial lines from the center to the circumference of the wheel body 10 . Furthermore, in the prior art, if a series of the holes 30 are formed in the wheel body 10 so as to be intersected by all of the radial lines from the center to the circumference of the wheel body 10 , the cutting wheel may be easily damaged during use since strength of the wheel body 10 is deteriorated.
  • the sandwich type cutting wheel is configured such that a copper plate 10 b having superior heat conductivity and noise reducing capacity is interposed between a pair of wheel bodies 10 a of steel and they are bonded by spot welding.
  • the sandwich type cutting wheel causes the manufacturing costs to increase at least two or three times as compared with a conventional wheel body 10 .
  • the wheel bodies 10 a of steel on both sides of the copper plate 10 b is thin and strength of the copper plate 10 b is considerably low, a wobbling phenomenon occurs which causes the wheel bodies 10 a to flap and vibrate during the use.
  • the cutting operation of the workpiece cannot be preferably performed.
  • the cutting operation is performed, there is a problem in that the life span of the cutting wheel is reduced since the cutting wheel is easily plastically deformed.
  • an object of the present invention is to provide a cutting wheel with blanks which makes it possible to maintain a strength at above a predetermined level and to considerably reduce a frictional noise by forming blanks, which include narrower portions with a constant width and wider portions, in a wheel body and then by filling the blanks with noise absorbing material, and a method for manufacturing the same.
  • a cutting wheel of which a wheel body is formed with at least one blank.
  • the blank is shaped in a line with a variable width, and the blank is filled with noise absorbing material.
  • any radial line of the wheel body intersects at least one of the blanks.
  • one ends of two of the blanks adjacent to each other are intersected by any one radial line of the wheel body.
  • the blank may comprise narrower portions shaped in a line with a constant width and wider portions wider than the narrower portions, the narrower portions and the wider portions are alternately arranged.
  • the wider portions may be provided at both ends and a center of the blank.
  • the noise absorbing material may include urethane, thermosetting resin, thermoplastic resin, metal, natural rubber, synthetic rubber or mixture of at least two thereof.
  • the metal may include copper or copper alloy powder.
  • a plating or adhesive layer may be formed on an inner surface of the blank.
  • the blank may be shaped in a curved line.
  • a method for manufacturing a cutting wheel comprises steps of: forming at least one blank shaped in a line with a variable width; preparing noise absorbing material to be filled in the blank; and filling the blank with the noise absorbing material.
  • any radial line of a wheel body of the cutting wheel intersects at least one of the blanks.
  • the method further comprises the step of forming a plating or adhesive layer on an inner surface of the blank before the blank is filled with the noise absorbing material.
  • the step of preparing the noise absorbing material may comprise the step of mixing at least one of urethane, thermosetting resin, and metal powder and hardening agent at a ratio of 1:1.
  • the method may further comprise the step of curing the noise absorbing material after the step of filling the blanks with the noise absorbing material.
  • the step of preparing the noise absorbing material may comprise the steps of mixing at least one of urethane and thermosetting resin and hardening agent at a ratio of 1:1 and mixing it with metal powder at a ratio of 1: 1.5.
  • the method may further comprise the step of curing the noise absorbing material after the step of filling the blanks with the noise absorbing material.
  • the step of curing the noise absorbing material may include the step of heating the noise absorbing material for 1 to 6 hours at 70 to 150° C.
  • the step of preparing the noise absorbing material may comprise the step of melting the noise absorbing material to flow into the blank.
  • the method may further comprise the step of curing the molten noise absorbing material after the step of filling the blank.
  • the step of preparing the noise absorbing material may comprise the step of cutting the noise absorbing material with a predetermined thickness and with a gap between the noise absorbing material and an inner surface of the blank.
  • the method may further comprise the step of pressing the noise absorbing material after the step of filling the blank.
  • the step of preparing the noise absorbing material may comprise the step of cutting the noise absorbing material in a size and shape so that it is interference-fitted into the blank.
  • the step of filling the blank may include the step of interference-fitting the noise absorbing material into the blank.
  • the step of preparing the noise absorbing material may comprise the steps of cutting the noise absorbing material in a size and shape so that it is wider than the blank and placing a surface of the wheel body to cover the blank with the noise absorbing material.
  • the step of filling the blank may include the step of cutting the noise absorbing material and simultaneously inserting it into the blank by a pressing process.
  • FIG. 1 is a front view showing a general cutting wheel
  • FIG. 2 is a front view showing a variety of conventional cutting wheels with blanks
  • FIG. 3 is a front view showing a conventional cutting wheel in which holes formed in a wheel body are filled with metal powder;
  • FIG. 4 is a perspective view showing a sandwich type cutting wheel for reducing noise
  • FIG. 5 is a front view showing a cutting wheel with blanks according to the present invention.
  • FIG. 6 is a view showing the operation of the cutting wheel with blanks shown in FIG. 5 ;
  • FIG. 7 is a front view showing a cutting wheel with blanks having a plurality of wider portions according to the present invention.
  • FIG. 8 is a view showing the operation of the cutting wheel with blanks shown in FIG. 7 ;
  • FIGS. 9 to 13 are front views showing a variety of embodiments of the cutting wheel with blanks according to the present invention.
  • FIG. 14 is a flow chart illustrating a manufacturing process of a cutting wheel with blanks according to one embodiment of the present invention.
  • FIGS. 15 to 17 are views showing processes of filling the blanks of the cutting wheel with blanks with noise absorbing material according to the manufacturing process of FIG. 14 ;
  • FIG. 18 is a flow chart illustrating a manufacturing process of a cutting wheel with blanks according to another embodiment of the present invention.
  • FIG. 19 is a view showing a process of filling the blanks of the cutting wheel with blanks with noise absorbing material according to the manufacturing process of FIG. 18 .
  • FIG. 5 is a front view showing a cutting wheel with blanks according to the present invention.
  • each of blanks 18 of the cutting wheel according to the present invention comprises narrower portions 25 which are shaped in a line with a constant width and wider portions 17 which are wider than the narrower portions and continuously connected thereto. That is, the blanks 18 are formed so as to block and absorb the frictional noise when the frictional noise caused from the contact between cutting tips 20 of the wheel body 13 and the workpiece is propagated from the circumference to the center.
  • the wider portions 17 are formed at both ends and the center of the blank 18 , so as to absorb the noise and vibration blocked by the narrower portions 25 and block the noise and vibration propagated from the circumference.
  • the blanks 18 are more preferably arranged circumferentially so that the wider portions 17 formed at the center and an end of each of the blanks 18 of the “S” shape are positioned on a concentric circle 23 and the wider portions 17 formed at the other opposite end of each of the blanks 18 is positioned on another concentric circle 24 , as shown in FIG. 5 .
  • the cutting wheel with blanks according to the present invention is manufactured by forming the blanks 18 by a laser cutting or press punching method so that the blanks 18 are intersected by any radial line 19 from a center 22 of a wheel body 13 . That is, it is preferred that the blanks 18 be formed so that when any one radial line is drawn from the center 22 toward the circumference of the wheel body 13 , the radial line intersects at least one of the blanks 18 .
  • the blanks 18 are fundamentally formed in a curved line such as an “S” shape. It is natural that the shapes of the blanks 18 be variously modified.
  • the number of the blanks 18 may also be selected properly in consideration of degrees of noise occurrence and strength of the cutting wheel in accordance with use of the cutting wheel.
  • the blanks 18 are formed so that an overlapping distance between two blanks adjacent to each other is properly designed.
  • the five blanks 18 of the “S” shape are formed so as to be equiangularly spaced around the center 22 of the wheel body.
  • the number of the blanks 18 may be selected on the basis of the consideration of degrees of frictional noise and strength applied to the wheel body 13 in accordance with an environment in which the cutting wheel is used as described above.
  • the blanks 18 according to the present invention has an additional feature in that the blanks 18 are filled with noise absorbing material. That is, the blanks 18 are filled with the noise absorbing material so that the blanks 18 formed in the wheel body 13 as above more improve the noise reducing capacity and an aesthetic appearance of the cutting wheel.
  • FIG. 6 is a view showing an operation of the cutting wheel with blanks according to the present invention.
  • the cutting wheel with blanks according to the present invention is used for cutting or processing a workpiece, the frictional noise and vibration is generated from the workpiece.
  • the impact and the frictional noise and vibration generated between the workpiece and the cutting tips 20 are propagated from gaps 12 or lower portions of the cutting tips 20 to the center 22 of the cutting wheel via the wheel body 13 . Then, some of the noise and vibration is reflected at a fastening hole for fastening the cutting wheel to an electric power device and then directed to the circumference of the cutting wheel. Thus, destructive and constructive interference between the propagated and reflected noises and vibrations occurs, causing a noise to increase at specified frequencies.
  • the impact and frictional noise and vibration is blocked by the blanks 18 , which are formed in the wheel body 13 so that the blanks 18 are intersected by all of the radial lines 19 from the center 22 toward the circumference of the wheel body 13 in order for the noise and vibration not to be propagated anymore. That is, the frictional noise and vibration, which is propagated to the center 22 of the cutting wheel, is blocked by the narrower portions 25 of the blanks 18 of the present invention. Then, the blocked frictional noise and vibration is propagated to the wider portions 17 formed at both sides of each the narrower portions 25 and is absorbed thereat. Since the wider portions 17 have a larger area and thus are filled with a larger amount of the noise absorbing material than the narrower portions 25 , the noise and vibration can be effectively absorbed.
  • the wider and narrower portions 17 and 25 of the blanks 18 function to block and absorb the noise and vibration, the main functions thereof are mainly described herein.
  • the wider portions 17 may be formed at more positions according to the environment in which the cutting wheel is used.
  • FIG. 7 is a front view showing the cutting wheel with blanks having a plurality of wider portions according to the present invention
  • FIG. 8 is a view showing an operation of the cutting wheel with blanks shown in FIG. 7 .
  • a plurality of blanks 18 shown in FIGS. 7 and 8 are arranged in a body of a cutting wheel.
  • the blank 18 comprises narrower portions 25 of straight or curved line with a constant width and wider portions 17 formed to be thicker than the narrower portions 25 , wherein the narrower portions 25 and the wider portions 17 are alternately connected to each other.
  • the cutting wheels shown in FIGS. 7 and 8 have an increased number of the wider portions, the present cutting wheel cause the noise to be reduced but the strength of the wheel body is deteriorated. However, since there is no difference in the operation and effect, the detailed description will be omitted.
  • FIGS. 9 to 13 are front views showing a variety of embodiments of the cutting wheel with blanks according to the present invention.
  • blanks 18 a having a constant width may be slantingly formed in the wheel body 13 along the circumferential direction so that the blanks 18 a are intersected by all of the radial lines 19 of the wheel body 13 , wherein the blanks 18 a may be filled with the noise absorbing material.
  • blanks 18 b may be slantingly formed in the wheel body 13 equiangularly along the circumferential direction so that the blanks 18 b are intersected by all of the radial lines 19 of the wheel body 13 , wherein a width of each blank 18 b becomes narrow uniformly along its lengthwise direction and the blanks 18 b may be filled with the noise absorbing material.
  • the blank shown in FIG. 9 may be formed with the wider portions as shown in FIG. 11 .
  • the blanks according to the present invention is not necessarily arranged so that the blanks are intersected by all of the radial lines 19 of the wheel body 13 . That is, those skilled in the art should note that the shape and arrangement of the blanks are not limited thereto.
  • FIG. 14 is a flow chart illustrating a manufacturing process of a cutting wheel with blanks according to one embodiment of the present invention.
  • the manufacturing process of the cutting wheel according to the present embodiment of the present invention comprises steps S 100 and S 110 of forming at least one blank in a wheel body, a step S 120 of preparing noise absorbing material to be filled in the blank, and steps S 130 to S 150 of filling the blank with the noise absorbing material.
  • the step of filling the blank with the noise absorbing material is a concept including processes of introducing the noise absorbing material with deformability into the blanks, curing the noise absorbing material and fixing it in the blanks, and grinding unnecessary portions of the noise absorbing material remaining on surfaces of the wheel body.
  • portions of a wheel body are first cut by a laser or press cutting method to form a blank having a shape as shown in FIGS. 5 to 13 (step S 100 ). Then, in order to securely fill the blank with the noise absorbing material, a plating layer of brass or copper is formed on an inner surface of the blank or adhesive is applied to the inner surface (step S 110 ). Thereafter, in order to minimize unnecessary portions of the noise absorbing material remaining on outer surfaces of the wheel body after filling the blank with the noise absorbing material, the noise absorbing material including natural rubber, synthetic rubber, thermoplastic resin or the like is cut according to the size and shape of the blank.
  • the noise absorbing material is cut in a size and shape so that it is interference-fitted into the blank, is inserted into the blank with a gap between the noise absorbing material and the inner surface of the blank, or covers the whole of the blank (step S 120 ).
  • step S 120 of preparing the noise absorbing material as above will be described in detail below referring to other figures.
  • a hot pressing process for securely filling the blank with the noise absorbing material is performed by applying heat and pressure to the wheel body and the noise absorbing material prepared in step S 120 (step S 130 ).
  • the noise absorbing material which is in a molten or semi-molten state by the heat and pressure, is cured (step S 140 ).
  • the cutting wheel with blanks is completely manufactured by grinding unnecessary portions of the noise absorbing material remaining on the surfaces of the wheel body which is generated by compression during the hot pressing process (step S 150 ).
  • FIGS. 15 to 17 are views showing processes of filling the blanks of the cutting wheel with blanks with noise absorbing material according to the manufacturing process of FIG. 14 .
  • FIG. 15 ( a ) shows that the noise absorbing material 14 in a solid state is interference-fitted into the blank 18 formed in the wheel body 13 , wherein the noise absorbing material 14 is cut in step S 120 of preparing the noise absorbing material so that it has a size and shape to be interference-fitted into the blank.
  • FIG. 15 ( b ) shows that the noise absorbing material 14 of FIG. 15 ( a ) is subjected to the hot pressing process according to step S 130 and then completely filled in the blank 18 .
  • the hot pressing process can be stably performed while the noise absorbing material 14 is fixed in the blank 18 .
  • a plating layer 15 of brass or copper be formed on the inner surface of the blank 18 , in order for the blank 18 to be securely filled with the noise absorbing material 14 .
  • FIG. 16 ( a ) shows that the noise absorbing material 14 in a solid state is inserted into the blank 18 formed in the wheel body 13 , wherein the noise absorbing material 14 is cut in step S 120 of preparing the noise absorbing material so that it has a size and shape to be inserted into the blank with the gap and a predetermined thickness.
  • the gap means an appropriately spaced distance between the noise absorbing material and the inner surface of the blank, as shown in FIG. 16 ( a ).
  • the predetermined thickness means a thickness or more which causes the whole of the noise absorbing material to be fully filled in the blank without residue after the noise absorbing material is deformed and fills up the gap.
  • FIG. 16 ( b ) shows that the noise absorbing material 14 of FIG.
  • the noise absorbing material 14 such as a rubber in solid state is changed to plastic state by the heat and pressure
  • the noise absorbing material 14 can be deformed laterally to be filled in the blank 18 by applying the heat and pressure upward and downward while the noise absorbing material 14 is inserted in the blank with the allowance gap between the noise absorbing material and the inner surface of the blank, as shown in the figure.
  • a plating layer 15 of brass or copper be formed on the inner surface of the blank 18 , in order for the blank 18 to be securely filled with the noise absorbing material 14 .
  • FIG. 17 ( a ) shows that the noise absorbing material 14 in a solid state is placed on a lower surface of the wheel body 13 while covering the blank 18 , wherein the noise absorbing material 14 is cut in step S 120 of preparing the noise absorbing material so that it has a size and shape wider than that of the blank 18 formed in the wheel body 13 .
  • FIG. 17 ( b ) shows that the noise absorbing material 14 of FIG. 17 ( a ) is subjected to the hot pressing process according to step S 130 and then completely filled in the blank 18 .
  • the noise absorbing material 14 such as a rubber in solid state can be deformed by the heat and pressure, the noise absorbing material 14 is cut and simultaneously inserted by the heat while being pushed by the pressure, as if the noise absorbing material 14 is punched by the blank 18 , and thus can be filled in the blank 18 .
  • Such a method results in a great loss of the noise absorbing material 14 .
  • the present method can cause the manufacturing time to reduce as compared with the methods illustrated in FIGS. 15 and 16 , it is suitable for mass production.
  • FIG. 18 is a flow chart illustrating a manufacturing process of a cutting wheel with blanks according to another embodiment of the present invention.
  • the manufacturing process of the cutting wheel according to the present embodiment of the present invention comprises steps S 200 and S 210 of forming at least one blank in a wheel body, step S 220 of preparing noise absorbing material and melting it, and steps S 230 to S 250 of filling the blank with the noise absorbing material molten in the previous step.
  • the step of filling the blank with the noise absorbing material is a concept including processes of introducing the noise absorbing material with fluidity into the blanks, curing the noise absorbing material and fixing it in the blanks, and grinding unnecessary portions of the noise absorbing material remaining on surfaces of the wheel body.
  • portions of a wheel body are first cut by a laser or press cutting method to form a blank having a shape as shown in FIGS. 5 to 13 (step S 200 ). Then, in order to securely fill the blank with the noise absorbing material, a plating layer of brass or copper is formed on an inner surface of the blank or adhesive is applied to the inner surface (step S 210 ). Thereafter, the noise absorbing material, such as natural rubber, synthetic rubber, or thermoplastic resin which can be fluid by heat and pressure, is molten (step S 220 ).
  • the noise absorbing material such as natural rubber, synthetic rubber, or thermoplastic resin which can be fluid by heat and pressure
  • step S 220 the noise absorbing material molten in step S 220 is introduced in the blank (step S 230 ) and then reacts with the adhesive or plating layer previously formed, so that the blank is filled with the noise absorbing material.
  • the detailed description concerning the step S 230 will be described in detail below referring to other figure.
  • the noise absorbing material which is filled in the blank in a molten or semi-molten state by the heat and pressure, is cured (step S 240 ).
  • step S 240 the cutting wheel with blanks is completely manufactured by grinding unnecessary portions of the noise absorbing material remaining on the surfaces of the wheel body which is generated by compression during the hot pressing process (step S 250 ).
  • FIG. 19 is a view showing a process of filling the blanks of the cutting wheel with blanks with noise absorbing material according to the manufacturing process of FIG. 18 .
  • FIG. 19 which is a view for concretely explaining the embodiment shown in FIG. 18 , shows an apparatus capable of injecting the molten noise absorbing material in the blank.
  • Such an apparatus comprises an upper mold 70 a, a lower mold 70 b, and a middle mold 70 c positioned between the upper and lower molds 70 a and 70 b.
  • the noise absorbing material 14 in a molten or semi-molten state is filled between the upper and middle molds 70 a and 70 c.
  • the wheel body is placed between the middle and lower molds 70 c and 70 b.
  • Nozzles 72 for injecting the molten noise absorbing material 14 into the blank of the wheel body are formed in the middle mold 70 c.
  • Hot plates 60 for transferring heat to the molds 70 a to 70 a are provided on the upper and lower portion of the upper and lower molds 70 a and 70 b.
  • the nozzles 72 are bored through the middle mold 70 c at positions corresponding to the blanks of the wheel body.
  • the noise absorbing material 14 with fluidity is injected and filled in the blanks through the nozzle 72 .
  • the noise absorbing material first flow into the wider portions through the nozzles 72 , gradually flows into the narrower portions, and then is filled in the blanks.
  • the noise absorbing material After the blank is filled with the noise absorbing material, the noise absorbing material is gradually cured by keeping it at about 200° for about five minutes. Then, the noise absorbing material mutually reacts with the plating or adhesive layer formed before the pressing process, so that the noise absorbing material is firmly filled in the blank.
  • the cutting wheel with blanks of the present invention may be manufactured by a method according to an additional embodiment of the present invention.
  • the noise absorbing material may comprise any one selected out of urethane, thermosetting resin, and metal powder.
  • the urethane and/or thermosetting resin may be mixed with the metal powder for the aesthetic appearance of the cutting wheel.
  • the blanks 18 may be filled solely with the metal powder. Any metal powder having a required, predetermined melting point or unique color may be used as the metal powder to be filled. However, copper or copper alloy powder is preferably used.
  • the urethane, thermosetting resin, or metal powder is mixed with hardening agent at a predetermined ratio, for example, 1:1. After the blanks 18 are filled with the mixture, the mixture is cured by heating it for 1 to 6 hours at 70 to 150° C. Since adhesive strength between the inner surface of the blank 18 and the urethane and/or thermosetting resin is low, the blank 18 is filled with the mixture containing the urethane and/or thermosetting resin after adhesive is applied onto the inner surface of the blank 18 .
  • the urethane or thermosetting resin and the hardening agent mixed at 1:1 may also be mixed with copper powder of 1.5 times thereof, and then, the blanks 18 are filled with said mixture and the mixture is cured by heating.
  • the blanks 18 may be filled with the metal powder such as copper or copper alloy powder without the urethane or thermosetting resin and the filler is cured by pressing and sintering.
  • a sound level meter for example, NA-27 of RION CO., LTD. of Japan, was installed at 1 meter from the cutting wheel to be tested and at the level of the center of the cutting wheel.
  • the cutting wheel was mounted to a cutting machine, for example, CEDIMA TABLE SAW CTS-60, which has 3 horsepowers and a maximum speed of 3600 rpm.
  • a completely cured concrete block of 300 mm ⁇ 300 mm ⁇ 40 mm was used as a workpiece.
  • the sound levels for the conventional cutting wheels with blank and the sandwich type cutting wheel do not particularly decrease in the frequency band below 250 Hz, but effectively decrease above 500 Hz, which is indicated in a shaded portion.
  • Amounts of the decreases for the cutting wheels correspond to order of the noise reducing effects (Wheel 4 ⁇ 5 ⁇ 2 ⁇ 3 as described above.
  • Wheel 4 i.e., the sandwich type cutting wheel
  • Wheel 5 i.e., the cutting wheel of the present invention
  • Table 3 the noise reducing effect is worse in order of Wheels 2 and 3 . That is, among Wheels 2 and 3 in which the conventional blanks are filled with silicone, Wheel 3 has an unsuitable shape of the blanks due to the small noise reducing effect, and Wheel 2 shows the noise reducing effect better than Wheel 1 , i.e., the general plane type cutting wheel, by average about 2 dB.
  • Wheel 5 shows the noise reducing effect better than Wheel 1 by 7 dB and than Wheels 2 and 3 by about 5 dB. In addition, Wheel 5 shows the noise reducing effect worse than Wheel 4 by about 2 dB.
  • Wheel 3 shows no noise reducing effect in the frequency band above 500 Hz
  • the shape of blanks of Wheel 3 is not suitable. That is, since the blanks of Wheel 2 are formed in the circumferential direction of the wheel body as shown in FIG. 2 ( b ), the noise reducing effect is exhibited to some degree. However, since the blanks of Wheel 3 are formed in the radial direction of the wheel body as shown in FIG. 2 ( c ), it is hard to block the noise generated from the cutting wheel. Thus, it is noted that the noise reducing effect of Wheel 3 is remarkably worse compared with the other cutting wheel. Accordingly, the above test results are supporting evidence experimentally showing that it is proper to form the blanks which intersect all of the radial lines from the center of the wheel body in order to block and absorb the noise as in the present invention.
  • the general average noise level (dB) is reduced by reducing the noise level in the high frequency band. Due to this, it is noted that noise reducing effect which is practically sensed by a user is better than the noise reducing effect which is numerically shown as above.
  • the cutting wheel with blanks according to the present invention shows the effective noise reducing effect as compared with the conventional cutting wheels, which is the reason why the blanks 18 of the cutting wheel according to the present invention always intersect all of the radial lines 19 from the center to the circumference of the cutting wheel, improving noise blocking effect.
  • the noise reducing effect is also improved by filling the blanks 18 with the noise absorbing material such as urethane. Particularly, since each of the blanks 18 consists of the wider and narrower portions 17 and 25 , the noise is more effectively blocked and absorbed.
  • the noise which is generated since the diamond cutting tips 20 and the wheel body 13 generate the impact and/or friction together with the workpiece, is mainly generated at the gaps 12 formed in the wheel body 13 . Accordingly, the generated noise is transmitted from the circumference to the center of the cutting wheel, and the transmitted noise to the center is reflected thereat. While the reflected noise is transmitted to the circumference again, an increased noise is generated at specified frequencies.
  • the conventional cutting wheel with blanks in which the narrow blanks are formed in the wheel body in a line shape by laser cutting and filled with silicone, has the problems in that the silicone with which the blanks is filled is easily removed during the use and the noise reducing effect does not largely improved due to the line shaped narrow blanks.
  • the feature of the present invention is in the blanks 18 consisting of the wider and narrower portions 17 and 25 instead of the uniformly narrow blanks.
  • the blanks 18 are filled with the noise absorbing material such as thermoplastic resin, natural rubber, synthetic rubber, the urethane, thermosetting resin, metal powder, or the mixture of the urethane or thermosetting resin and the metal powder, instead of the silicone, and the noise absorbing material is cured.
  • the noise absorbing material is prevented from being removed during the use of the cutting wheel.
  • the blanks 18 intersect all of the radial lines from the center to the circumference of the cutting wheel, the noise reducing effect can be considerably improved as good as the conventional sandwich type cutting wheel.
  • the blanks of the cutting wheel are formed so that the blanks intersect all of the radial lines from the center to the circumference of the cutting wheel and each of the blanks consists of the wider and narrower portions in order to block and absorb the noise.
  • the noise and vibration is considerably decreased as compared with the general plane type cutting wheel and the conventional cutting wheel with blanks.
  • the cutting wheel with blanks according to the present invention can absorb the noise and vibration as good as the sandwich type cutting wheel having the superior noise reducing effect
  • the cutting wheel of the present invention is considerably high in strength and is inexpensive to manufacture with 1 ⁇ 2 to 1 ⁇ 3 costs compared with the sandwich type cutting wheel.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Braking Arrangements (AREA)
US11/074,512 2004-03-05 2005-03-07 Cutting wheel with blank and manufacturing method thereof Abandoned US20050193866A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
KR2004-15191 2004-03-05
KR1020040015191A KR100466509B1 (ko) 2004-03-05 2004-03-05 관통홈이 형성된 절삭휠 및 그 제조방법
KR2004-76567 2004-09-23
KR1020040076567A KR100671884B1 (ko) 2004-09-23 2004-09-23 소음 저감 절삭휠 및 그 제조방법

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070056426A1 (en) * 2003-10-17 2007-03-15 Satoru Nishio Disk-like tool
US20110232422A1 (en) * 2005-07-06 2011-09-29 Mitsuboshi Diamond Industrial Co., Ltd. Scribing wheel for brittle material and manufacturing method for same, as well as scribing method, scribing apparatus and scribing tool using the same
US20150056901A1 (en) * 2013-08-23 2015-02-26 Saint-Gobain Abrasives, Inc. Abrasive article
CN110026609A (zh) * 2019-04-26 2019-07-19 山东黑旋风锯业有限公司 一种低噪音锯片及其生产方法
US20190234559A1 (en) * 2018-01-31 2019-08-01 Hollymatic Corporation Method and system to monitor and shut down saw
USD871878S1 (en) 2018-05-14 2020-01-07 Black & Decker Inc. Diamond blade
CN112991311A (zh) * 2021-03-29 2021-06-18 深圳大学 车辆超重检测方法、装置、系统及终端设备

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ITUD20070030A1 (it) * 2007-02-13 2008-08-14 Casals Herramientas Electricas Sl Procedimento di finitura per un utensile per la lavorazione del legno, o materiali affini, apparecchiatura per la finitura di tale utensile, ed utensile cosi finito
DE102021208300A1 (de) * 2021-07-30 2023-02-02 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein Rotierendes oder oszillierendes Werkzeug versehen mit Metamaterialien zur Reduktion von Schallabstrahlung und Vibrationen

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US3513821A (en) * 1968-02-05 1970-05-26 Ferro Corp Abrasive cut-off wheel
US3812755A (en) * 1970-12-14 1974-05-28 Nora Gomex Ab Product, preferably a rotatable working tool, e.g., a saw blade
US3799025A (en) * 1971-07-23 1974-03-26 Garbo P Vibration-damped rotatable cutting disk
US4106382A (en) * 1976-05-25 1978-08-15 Ernst Salje Circular saw tool
US4201103A (en) * 1977-10-14 1980-05-06 Ernst Salje Circular saw tool
US4867025A (en) * 1978-07-28 1989-09-19 Gomex Verktyg Ab Circular saw blade
US4187754A (en) * 1978-09-21 1980-02-12 Beaty Loma B Noise dampened rotary saw blade
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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070056426A1 (en) * 2003-10-17 2007-03-15 Satoru Nishio Disk-like tool
US8042443B2 (en) * 2003-10-17 2011-10-25 Kanefusa Kabushiki Kaisha Disk-shaped tool with vibration reduction
US20110232422A1 (en) * 2005-07-06 2011-09-29 Mitsuboshi Diamond Industrial Co., Ltd. Scribing wheel for brittle material and manufacturing method for same, as well as scribing method, scribing apparatus and scribing tool using the same
US20150056901A1 (en) * 2013-08-23 2015-02-26 Saint-Gobain Abrasives, Inc. Abrasive article
US9427846B2 (en) * 2013-08-23 2016-08-30 Saint-Gobain Abrasives, Inc. Abrasive article
US20190234559A1 (en) * 2018-01-31 2019-08-01 Hollymatic Corporation Method and system to monitor and shut down saw
USD871878S1 (en) 2018-05-14 2020-01-07 Black & Decker Inc. Diamond blade
USD890585S1 (en) 2018-05-14 2020-07-21 Black & Decker Inc. Diamond blade
CN110026609A (zh) * 2019-04-26 2019-07-19 山东黑旋风锯业有限公司 一种低噪音锯片及其生产方法
CN112991311A (zh) * 2021-03-29 2021-06-18 深圳大学 车辆超重检测方法、装置、系统及终端设备

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